Mattress and removable mattress cover assembly

ABSTRACT

A removable mattress cover assembly includes a removable mattress cover that attaches to an upright wall assembly. The upright wall assembly includes an upright wall that attaches to a top of a mattress base and one or more wall fasteners attached at or near the top of the upright wall. The removable mattress cover includes cover fasteners that mate with respective wall fasteners to attach the cover to the upright wall. When the cover fasteners are attached to the wall fasteners, the removable mattress cover lays over the top of the mattress base, and the upright wall is nearly perpendicular to the removable mattress cover. This allows a fill material that is nearly the same size as the top of the mattress to be inserted beneath the removable mattress cover. The fasteners can project upwardly, away from the top of the mattress base, making the fasteners easily accessible from above.

RELATED APPLICATION DATA

[0001] This application claims the benefit of U.S. Provisional PatentApplication Serial No. 60/440,560, filed on Jan. 16, 2003, which ishereby incorporated by reference.

FIELD OF THE INVENTION

[0002] The present invention relates to mattresses and, moreparticularly, to a removable mattress cover assembly, and a method offastening a removable mattress cover to a mattress.

BACKGROUND OF THE INVENTION

[0003] Traditionally, mattresses are an expensive, but disposable pieceof bedroom furniture. As mattress covers wear, become soiled or torn, orcomponents beneath the cover wear and sag, consumers discard themattress because the components cannot be easily repaired or replaced.In fact, consumers rarely, if ever, attempt to reconstruct or repair anold mattress with new components.

[0004] Mattress consumers in the marine and recreational vehicle (RV)industry are particularly sensitive to mattress costs because therigorous environmental conditions to which these mattresses are exposedusually lead to replacing the mattresses more frequently.

[0005] One way to protect a mattress from wear is to use a removablemattress cover. Mattress covers typically cover a top surface of themattress. Some mattress covers encase the entire mattress, and othermattress covers use straps or other means to hold the mattress cover inplace on the mattress. Mattress covers, however, have not been withoutdrawbacks.

[0006] In one particular mattress cover, a type that encases a mattress,a zipper closure on a side panel below the top surface allows themattress to be inserted into and removed from the mattress cover.

[0007] When a mattress and mattress cover are installed in the berth ofa boat, the side walls of the berth block access to the zipper or otherdevice used to hold the cover to the mattress. Consequently, a user mustpull and tug the mattress cover top to reach the zipper or release otherdevices that wrap around and hold the cover to the mattress. This can bevery difficult because the user usually must stretch across or lay ontop of the mattress cover to get to certain portions of the mattress.Oftentimes, the pulling and tugging on the top of the cover is soburdensome and inconvenient that the user resorts to removing the entiremattress from the berth to get the cover on or off.

[0008] A similar problem arises in home use where a headboard orfootboard may make it difficult to apply or remove the cover. Anotherproblem is that some mattress covers limit the thickness of the mattressor the fill material under the mattress cover. This is particularly truewhen the mattress cover is snug to the top of the mattress, in whichcase there is little space between the mattress and the mattress cover.In this situation, over-stuffing stresses the fasteners and impairstheir ability to hold the cover on the mattress or makes it difficult orimpossible to get the mattress into an enclosing-type cover. Even if theuser manages to stuff such a mattress into the cover, closing it can beeven more difficult. If the cover is not closed, the mattress will workitself out of the cover.

[0009] Another problem with some mattress covers, particularly with asnug-fitting mattress cover, is that the tautness in the cover causes ahammocking effect whereby, for example, a sleeper's trunk sinks lowerinto the mattress while the mattress pushes up on the arms, legs andhead. To reduce the hammocking effect, the user may attempt to ease thetautness at the zipper by removing material from between the mattresscover and the mattress. Of course, this may adversely affect thecushioning properties that the user wants. Thus, the user can be caughtin a trade-off between having a desired amount of cushioning with anaccompanying hammocking effect or having a less desirable cushioningwith less noticeable hammocking.

[0010] Yet another problems that some other mattress covers mask thefeel of the inner material in the mattress or between the mattress andmattress cover. In some instances the mattress cover is a quiltedmaterial, for example, and the quilted material masks the feel andcomfort qualities of the inner material. Some mattresses also sufferfrom inner material migration, bunching, or buckling when a sleeper laysdown on, rolls over on, or gets up from the mattress.

[0011] Conventional mattresses also may be equipped with perimetergussets or inner attachment devices that, in effect, reduce the area ofthe sleeping surface. For example, a conventional pillow-top stylemattress typically has a three to five inch gusset, or inward V-shapeconstruction that divides the base mattress from a softer “pillow”mounted on top of the base mattress. The gusset or inward V-shapematerial, in effect, generally precludes inner fill materials fromextending to the edge of the mattress. The inner fill material below themattress cover, typically the material in which the user seeks comfort,is therefore shorter in length and width than the overall length andwidth of the mattress. Consequently, the actual sleeping area of themattress is smaller.

[0012] The weight of an additional sleeping partner or a large weightdisparity between sleeping partners magnifies these problems.

SUMMARY OF THE INVENTION

[0013] The present invention generally relates to a mattress including aremovable mattress cover that is easily attachable and removable fromabove, and a mattress cover assembly that enables fill material that issubstantially the same size as the top of the mattress to be insertedbelow the removable mattress cover.

[0014] According to one aspect of the invention, a removable mattresscover assembly for attachment to a mattress base includes an uprightwall assembly including an upright wall for attachment to a top of themattress base and one or more wall fasteners attached at or near the topof the upright wall, and a removable mattress cover including one ormore cover fasteners that are matable with respective wall fasteners,wherein when the one or more cover fasteners are fastened to the one ormore wall fasteners, the removable mattress cover covers the top of themattress base and the upright wall is substantially perpendicular to theremovable mattress cover.

[0015] A second row of a plurality of wall fasteners may be attached tothe upright wall and spaced downwardly from the fasteners at or near thetop of the upright wall.

[0016] According to another aspect of the invention, a mattresscombination includes the removable mattress cover assembly and amattress base with the upright wall attached to the mattress base. Themattress base may be part of a newly constructed mattress or an existingmattress that is retrofitted with the removable mattress assembly.

[0017] According to another aspect of the invention, there is provided amethod of making a mattress, including the steps of providing a mattressbase and an upright wall; attaching the upright wall to a top of themattress base; attaching one or more wall fasteners at or near the topof the upright wall; providing a removable mattress cover including oneor more cover fasteners that are matable with respective wall fasteners;and fastening the one or more cover fasteners to respective wallfasteners, whereby the removable mattress cover covers the top of themattress base and the upright wall is substantially perpendicular to theremovable mattress cover.

[0018] The mattress base may include an upright outer wall dependingfrom the top, and the upright wall may be attached to the mattress basein substantially coplanar relation to the upright outer wall of themattress base. Moreover, a layer of fill material having substantiallythe same footprint as the footprint of the top of the mattress base maybe inserted between the top of the mattress base and the removablemattress cover.

[0019] According to yet another aspect of the invention, there isprovided a method of retrofitting an existing mattress with a removablemattress cover that includes the steps of: attaching an upright wall toa top of the existing mattress; attaching one or more wall fasteners ator near the top of the upright wall; providing a removable mattresscover including one or more cover fasteners that are matable withrespective wall fasteners; and fastening the one or more cover fastenersto respective wall fasteners, whereby the removable mattress covercovers the top of the existing mattress and the upright wall issubstantially perpendicular to the removable mattress cover.

[0020] According to an aspect of the invention, a removable mattresscover assembly for attachment to a mattress base, includes an uprightwall assembly including an upright wall for attachment to a top of themattress base and one or more wall fasteners attached at or near the topof the upright wall; and a removable mattress cover including one ormore cover fasteners that are matable with the respective wallfasteners, wherein when the one or more cover fasteners are fastened torespective wall fasteners, the removable mattress cover covers the topof the mattress base and the cover fasteners project upwardly relativeto the top of the mattress base.

[0021] According to an aspect of the invention a mattress includes amattress base; one or more upper surface fasteners attached to a top ofthe mattress base; and a removable mattress cover including one or morecover fasteners that are matable with respective upper surfacefasteners; wherein when the one or more cover fasteners are fastened tothe respective upper surface fasteners, the removable mattress covercovers the top of the mattress base and the cover fasteners projectupwardly relative to the top of the mattress base.

[0022] According to yet another aspect of the invention, there isprovided a method of making a mattress, including the steps of:providing a mattress base; attaching one or more upper surface fastenersto a top of the mattress base; providing a removable mattress coverincluding one or more cover fasteners that are matable with therespective of upper surface fasteners; and fastening the one or morecover fasteners to respective upper surface fasteners, whereby theremovable mattress cover covers the top of the mattress base and thecover fasteners project upwardly relative to the top of the mattressbase.

[0023] According to still another aspect of the invention, there isprovided a method of retrofitting an existing mattress with a removablemattress cover, including the steps of: attaching one or more uppersurface fasteners to a top of the existing mattress; providing aremovable mattress cover including one or more cover fasteners that arematable with respective upper surface fasteners; and fastening the oneor more cover fasteners to respective upper surface fasteners, wherebythe removable mattress cover covers the top of the existing mattress andthe cover fasteners project upwardly relative to the top of the existingmattress.

[0024] The present invention comprises a mattress including a removablemattress cover that enables a consumer to easily replace a soiledmattress cover, easily change surface pads, alter the firmness factors,protect the consumer's investment by waterproofing the mattress contentsunder the cover, or replace components without having to replace theentire mattress. Advantageously, the initial investment in the mattressis extended due to the flexibility in changing or modifying the mattressto individual firmness preferences and needs. The mattress can beone-sided or two-sided. A wide range of end users in the mattressindustry, including health care facilities, marine, consumer home use,commercial hotel, antique, and RV market segments, can utilize themattress according to the present invention.

[0025] The foregoing and other features of the invention are hereinafterfully described and particularly pointed out in the claims, thefollowing description and the annexed drawings setting forth in detailan embodiment of the invention, such being indicative, however, of butone of the various ways in which the principles of the invention may beemployed.

BRIEF DESCRIPTION OF DRAWINGS

[0026]FIGS. 1A & 1B are respective front and back perspective views ofan upright wall of an upright wall assembly of a mattress according toan embodiment of the present invention, the upright wall being shownspread laterally outward.

[0027]FIG. 2 is a perspective view of the upright wall of FIG. 1 sewnaround a perimeter of a bottom to form an upright wall assembly, theupright wall assembly and the bottom together forming a cavity forreceiving inner fill materials.

[0028]FIG. 3 is a perspective view of the upright wall assembly of FIG.2 with a flange sewn around the perimeter of the bottom of the uprightwall assembly.

[0029]FIG. 4 is a bottom perspective view of upright wall assembly ofFIG.3.

[0030]FIG. 5 is a perspective view of the upright wall assembly of FIGS.3 and 4 sewn to a mattress base, the flange being inward of and adjacentto an upright outer wall of the mattress base.

[0031]FIG. 6 is a perspective view of a mattress according to anembodiment of the invention, partially exploded to show a removablemattress cover removed from the upright wall assembly.

[0032]FIG. 7 is a perspective view of a pair of mattresses, eachaccording to an embodiment of the invention, and each similar to themattress of FIG. 6.

[0033]FIG. 8 is a perspective view of a mattress according to anembodiment of the present invention, with various layers of the mattresspartially folded back.

[0034]FIG. 9 is a side elevational view of the mattress of FIG. 8,partially broken to show layers of inner fill material.

[0035]FIG. 10 is an end elevational view of the mattress of FIG. 8.

[0036]FIG. 11 is a perspective view of a retrofitted existing mattressand a removable mattress cover according to an embodiment of the presentinvention, the removable mattress cover being shown partially foldedback upon itself and partially fastened to the existing mattress.

[0037]FIG. 12 is a perspective view of a retrofitted existing mattressand a removable mattress cover according to an embodiment of the presentinvention, the removable mattress cover being shown partially foldedback upon itself and partially fastened to the existing mattress.

[0038]FIG. 13 is a perspective view of a retrofitted existing mattress,an upright wall assembly, and a removable mattress cover according toanother embodiment of the present invention, the removable mattresscover being shown partially folded back upon itself.

[0039]FIG. 14 is a perspective view of the retrofitted existing mattressof FIG. 13, upright wall assembly, and removable mattress cover.

[0040]FIG. 15 is a perspective view of a retrofitted existing mattressand a removable mattress cover according to an embodiment of the presentinvention, the removable mattress cover being shown partially foldedback upon itself.

[0041]FIG. 16 is a perspective view of a pair of removable mattresscovers and an existing mattress that has been retrofitted on the top andbottom thereof to accommodate the removable mattress covers.

[0042]FIG. 17 is a perspective view of a retrofitted existing mattress,a pair of upright wall assemblies, and a pair of removable mattresscovers, according to an embodiment of the present invention.

[0043]FIG. 18 is a perspective view of an existing mattress and anupright wall assembly mounted thereto with multiple rows of fastenersaccording to an embodiment of the present invention.

[0044] In the detailed description that follows, where consideredappropriate, reference numerals have been repeated among the figures toindicate corresponding elements, regardless of whether they are shown indifferent embodiments of the invention. To illustrate the presentinvention in a clear and concise manner, the drawings may notnecessarily be to scale and certain features may be shown in somewhatschematic form. For example, the dimensions of some of the elements areexaggerated relative to each other for clarity.

DETAILED DESCRIPTION

[0045]FIGS. 1 through 6 illustrate sequential steps of a method ofconstructing a mattress 10 in accordance with an embodiment of thepresent invention. In FIG. 6, an exemplary completed exemplary mattress10 in accordance with the present invention typically includes amattress base 12, an upright wall assembly 14 and a removable mattresscover 20. The removable mattress cover 20 fastens to an upper surface ofthe upright wall assembly 14 with one or more suitable fasteners thatare easily accessible from above the mattress 10. Therefore, a user caneasily detach and reattach the removable mattress cover 20 with respectto the upright wall assembly 14, even within the tight confines of theberth of a boat. Moreover, owing to the construction of the upright wallassembly 14 with respect to the mattress base 12, the removable mattresscover 20 flexes and moves freely, alleviating the hammocking effectexhibited by some prior mattress covers. The user can construct themattress 10 anew or retrofit an existing mattress to include themattress cover 20.

[0046] Turning to a more detailed description of the mattress 10, FIGS.1A,1B and 2 show an upright wall 24 and a bottom or bottom layer 28 ofthe upright wall assembly 14. FIGS. 1A and 1B show respective outer andinner faces of the upright wall 24 spread laterally outward. The uprightwall 24 may be made of any suitable material, for example, amulti-needle quilted material. A thicker material (for example one halfinch ({fraction (1/2)}″) polyurethane foam) may additionally oralternatively be used in the upright wall 24 to add durability, wearresistance and longevity. Alternatively, the upright wall assembly 14can have a conventional border material, generally {fraction (3/16)}″ or{fraction (1/4)}″ thick. An indented reinforcing stitch 30 is serged toboth the top and the bottom of the upright wall 24. The bottom layer 28of the upright wall assembly 14 may be made of any suitable material,for example, a cloth material, or a multi-needle quilted material.

[0047] The upright wall 24 is sewn, for example by a single needlestitch or serging, to the perimeter of the bottom layer 28. This placesthe upright wall 24 substantially perpendicular to the bottom layer 28.Together, the upright wall 24 and bottom layer 28 form the upright wallassembly 14. As shown in FIG. 2, because the upright wall 24 is stitchedto the perimeter of the bottom layer 28 in a relatively perpendicularmanner, the upright wall assembly 14 forms a cavity that can receive afill material, such as a foam material, cotton, fiber, silk or wool,having a peripheral dimension or footprint substantially the same as theperipheral dimension or footprint of the bottom layer 28 of the uprightwall assembly 14. Unlike prior mattress assemblies, the upright wallconstruction is not undulated, interrupted or restricted by perimetergussets or extra inner attachment devices. Of course, depending on suchfactors as the stitching or sewing equipment and styles, or thematerials used, the upright wall 24 may have some areas that are notperpendicular or at 90 degrees in some portions. In this regard, theterm “substantially perpendicular” as used herein means at approximatelyninety degrees with respect to the reference surface, or plus or minusabout fifteen degrees from vertical. As will be appreciated, the moreperpendicular or vertical that the upright wall 24 is relative to thebottom layer 28, the larger the volume of the cavity of the upright wallassembly 14.

[0048] In the illustrated embodiment, the bottom layer 28 of the uprightwall assembly 14 also functions as a top layer of the mattress base 12.As further described below, the bottom layer 28 may alternatively beindependent of and lie adjacent to an already-existing top layer of amattress base or existing mattress. The top layer of the mattress baseor mattress may be reinforced by serging with an inner reinforcingstitch followed by a 1{fraction (1/4)}″ edging sewn to its perimeter.

[0049] Referring to FIGS. 3 and 4, a flange 32 is stitched at theperimeter of the bottom layer 28 and extends away from the upright wall24. The flange 32 may be made of any suitable material, for example,cotton, synthetic fibers, non-woven fibers, polyester, or even a tickmaterial having a cotton-polyester blend. A serge stitch may be used toreinforce the flange attachment to the upright wall assembly 14.

[0050] The flange 32 attaches the upright wall assembly 14 to themattress base 12. As shown in FIG. 5, the mattress base 12 includes anupright outer layer or wall 38 made of, for example, a quilt material,and an inner fill material such as foam (not shown). Although notspecifically shown in FIG. 5, the flange 32 is attached inward of andadjacent to the upright outer layer 38. The flange 32 attaches to theinner fill material by a suitable connecting element, for example, glue,hooks and loops, and hog rings. The flange 32, or portions thereof, maybe stitched to the upright wall layer 38, to reinforce same.

[0051] Alternatively, the flange 32 may extend outside the upright outerlayer 38 of the mattress base 12, in which case the upright outer layer38 of the mattress base 12 attaches to the inner fill material and theupright outer layer 38 attaches to the flange 32. The upright wallassembly 14 may be connected to the mattress base 12 by means other thanby the flange 32, for example, by stitching the bottom of the uprightwall 24 of the upright wall assembly 14 directly to the mattress base12. In another alternative, the flange 32 forms the upright outer layer38 of the mattress base 12; that is, the flange 32 and upright outerlayer 38 are the same component.

[0052] When the upright wall assembly 14 is attached as shown in FIG. 5,the upright wall 24 is substantially coplanar with respect to theupright outer layer 38 of the mattress base 12. In addition, since theupright wall 24 is in a relatively perpendicular to the bottom layer 28of the upright wall assembly 14, and generally the top layer of themattress base 12, the upright wall assembly 14 forms a cavity that iscapable of receiving a fill material having a peripheral dimension orfootprint substantially the same as the peripheral dimension orfootprint (as defined by the upright outer layer 38) of the mattressbase 12.

[0053] In any of the embodiments, any sewn or stitched material may bereinforced, for example by serging. For example, in one embodiment, areinforcing stitch serges the upright wall 24 to the mattress base 12.Or, a tape edge material serges corner stitches of the mattress base 12to reinforce same. Still further, a 1{fraction (1/4)}″ wide tape edgematerial, for example, may be used to reinforce the perpendicularupright wall 24 and the upright outer layer 38 of the mattress base 12,such as at spaced attachment points, to reinforce same.

[0054] Referring now to FIG. 6, removable means for attachment,including one or more wall fasteners 50, for example, a plurality ofsnap fasteners, are affixed at or near an upper portion of the uprightwall assembly 14. A durable tape edge material, such as polyester, vinylor nylon fabric may be serged to the upper portion before attaching thewall fasteners 50 to provide additional support for the wall fasteners50 and to reinforce the upright wall 24.

[0055] Referring briefly again to FIG. 5, a pair of adhesive strips 54are adhered to the bottom layer 28 of the upright wall assembly 14. Theadhesive strips 54 hold an inner foam material or other suitable fillmaterial 58 inside the cavity of the upright wall assembly 14, as isillustrated in FIG. 6. Any suitable adhesive may be used, for example,double sided adhesive tape, hooks and loops, and/or glue. As will beappreciated, the quantity, type and positioning of the adhesive strips54 will facilitate the manner by which the adhesive strips 54 hold thefill material 58 inside the cavity. For example, if it is desired thatthe center of the fill material 58 have greater freedom to shift, thenthe adhesive strips 54 may be positioned at the perimeter of the bottomlayer 28. Alternatively, if it is desired that the perimeter of the fillmaterial 58 have greater freedom to shift, then the adhesive strips 54may be positioned at the center of the bottom layer 28. Othercombinations are possible, as will be appreciated.

[0056] The removable mattress cover 20 covers the cavity provided by theupright wall assembly 24. The removable mattress cover 20 may compriseone or more of many combinations of tickings with properties that arewaterproof, vinyl, cloth, exotic blends, fire retardant, anti-flammable,hypo-allergenic, anti-fungal, anti-bacterial, cotton, wool, polyester,leather and blends, combinations, and other materials common to themattress or upholstery industry, depending on the intended use andaesthetics. Additionally, the removable mattress cover 20 may be asmooth top or multi-needled quilted with many different materials orcombinations or percentage mixes of cotton, wool, silk, leathersynthetic fibers, foam with different densities, I.L.D.'s, andthicknesses or convolutions, and “zoned” cuts, and styles common to theindustry such as latex, visco-elastic or polyurethane foam, depending onfirmness factors, aesthetics, and other concerns.

[0057] The removable mattress cover 20 includes one or more coverfasteners 60, for example snap fasteners, corresponding to the wallfasteners 50 of the upright wall assembly 24. As shown in FIG. 6, thecover fasteners 60 attach to the removable mattress cover 20 at or nearthe perimeter thereof and face or project upwardly relative to the topsurface of the removable mattress cover 20. It will be appreciated thatthe removable mattress cover 20 may be reinforced by serging with aninner reinforcing stitch followed by a 1{fraction (1/4)}″ edging sewn toits perimeter.

[0058] The cover fasteners 60 fasten to the respective wall fasteners 50thereby to secure the removable mattress cover 20 to the upper portionof the upright wall assembly 14. As a result, the fill material 58 issandwiched between the removable mattress cover 20 and the mattress base12.

[0059] As shown in FIG. 6, when fastened to the upright wall 24 theremovable mattress cover 20 is substantially perpendicular to theupright wall 24 and the cover fasteners 60 thereof project upwardly withrespect to the top layer of the completed mattress. As further describedbelow, the upward projection of the cover fasteners 60 makes them moreeasily accessible from above.

[0060] As will be appreciated, the mattress shown in FIG. 6 has anunusual shape compared to a conventional mattress. Following is adescription of alternative embodiments of mattresses and removablemattress cover assemblies having a generally more conventionalrectangular shape. It will further be appreciated that the claimedinvention contemplates any size mattress, for example, king, queen,twin, and any shape mattress, for example, rectangular, non-rectangular,round, oval, triangular, or heart-shape.

[0061]FIG. 7 shows a pair of mattresses 62 in accordance with thepresent invention, each being similar to the mattress 10 of FIG. 6,except larger and rectangularly shaped. In this and each of the laterdescribed embodiments of the present invention like reference numeralscorrespond to like components, and superfluous description in thisregard is omitted.

[0062] Each mattress 62 includes a removable mattress cover 64 inaccordance with the present invention. A plurality of cover fasteners 60attach to the perimeter of the removable mattress cover 64. The wallfasteners 50 on an upper rim portion of the mattresses 62 fasten torespective cover fasteners 60, thereby fastening the removable mattresscover 64 to the upright wall assembly 68. As is shown in FIG. 7, the twomattresses 62 are positioned in abutting relation with respect to oneanother. The cover fasteners 60 project upwardly with respect to the toplayers of the mattresses 62, and more particularly the top surfaces ofthe removable mattress covers 64. Advantageously, even with themattresses 62 arranged in abutting relation, the cover fasteners 60 areunrestricted and easily accessible from atop the mattresses 62. In tightquarters such as the berth of a boat, this easy accessibility to thecover fasteners 60 in accordance with the present invention simplifiesdetachment and reattachment, or replacement, of the removable mattresscover 64.

[0063] FIGS. 8-10 show another embodiment of a mattress 80 in accordancewith the present invention. The mattress 80 includes a removablemattress cover 82 (for example, a tick layer), a first foam layer 84,and a second foam layer 86. In FIG. 8, the removable mattress cover 82,the first foam layer 84, and the second foam layer 86 are shownpartially folded back upon themselves. The second foam layer 86 adheresto the bottom layer 28 of the upright wall assembly 94 of the mattress80 via the adhesive strips 54. As will be appreciated, adhesive strips54 may also be disposed between the first and second foam layers 84 and86, or between the removable mattress cover 82 and the first foam layer84, as may be necessary or desired to effect a different feel in thefill materials.

[0064] A plurality of cover fasteners 60 are attached to the perimeterof the removable mattress cover 82, and a plurality of wall fasteners 50matable with the cover fasteners 60 are attached to the upper rimportion of the upright wall assembly 94. FIGS. 9 and 10 show theremovable mattress cover 82 fastened to the upright wall assembly 94 viathe cover fasteners 60 and mating wall fasteners 50.

[0065] As the mattress 80 demonstrates, the removable mattress cover 82and the upright wall assembly 94 allow the firmness level to be adjustedby layering the fill material. As will be appreciated, the firmnesslevel can be adjusted by adding or removing fill material, as desired,to meet the specific needs of an individual, for example, extra firm,firm, medium firm, plush firm, soft. Also, as technology and productsprogress, new products with different properties can be inserted intothe cavity of the upright wall assembly 94. The removable mattress cover82 also enables different levels of firmness in different areas orsections to accommodate the personal preferences of different sleepers.For example, multiple different fill materials can be positioned inlaterally adjacent sides of the fill cavity. The fill material can alsoprovide zone-different firmness levels for support at specific targetedareas where desired along the body length, such as lumbar support, forexample. The cavity can be filled with new sleep products as technologyadvances, offering new comfort levels and “feels.”

[0066] As was alluded to above, the present invention is not limited toa new mattress incorporating a removable mattress cover assembly. Theconcepts of the present invention may also be applied to existing or“used” mattresses. FIGS. 11 and 12 each show an exemplary embodiment ofthe present invention in which an existing mattress 100 and 102 has beenretrofitted to accommodate a removable mattress cover 104. In the FIGS.11 and 12 embodiments, there is no upright wall assembly in which wallfasteners are secured. Instead, a plurality of upper surface fasteners108 attach at or near the perimeter of the existing mattress 100 in thetop layer thereof as shown. In the FIG. 11 existing mattress 100, theupper surface fasteners 108 are attached as by stitching to the toplayer of the existing mattress 100. The upper surface fasteners 108 maybe attached to an inner structural element of the existing mattress 100to provide further support thereto. In the FIG. 12 existing mattress104, the upper surface fasteners 108 are attached to a tape edgematerial at the perimeter of the existing mattress 102. In the existingmattresses 100 or 102, the cover fasteners 60 fasten to thecorresponding mating upper surface fasteners 108 thereby to fasten theremovable mattress cover 104 to the existing mattress 100 or 102.

[0067] The mattresses 100 and 102 realize several advantages,particularly in the marine and RV industry. In the marine and RVindustry, the cover of a mattress is exposed to an extraordinary amountof wear due to, for example, temperature and humidity fluctuations,sunlight, moisture, and other environmental factors to which householdmattresses may not be exposed. Meanwhile, however, the innards of themattress, for example the fill material or the inner support structure,remain able to function in substantially the same manner as they didwhen new. Consequently, by being able to retrofit the existing mattressof the marine or RV user with a removable mattress cover in accordancewith the present invention, there is no need to purchase a new mattresseach time the cover wears. Moreover, as with the earlier describedmattresses, the removable mattress cover 104 is easily accessible fromthe top surface thereof.

[0068]FIGS. 13 and 14 show another embodiment of an existing mattress120 that has been retrofitted with a removable mattress cover 124. Here,an upright wall assembly 130 is attached to the existing mattress 120.The upright wall assembly 130 includes an upright wall 132 and a zipper136 stitched or otherwise attached to the upper rim portion of theupright wall 132. The upright wall assembly 130 is attached to theexisting mattress 120 in a manner such as that described above withrespect to the FIG. 6 embodiment in which the mattress is constructedanew. In this regard, the bottom of the upright wall 132 is attacheddirectly to the top of the upright outer layer 140 of the existingmattress 120. Additionally or alternatively, a bottom layer (not shown)of the upright wall assembly 130, similar to the previously describedbottom layer 28 (FIGS. 2-4), may be juxtaposed with respect to a toplayer 142 of the existing mattress 120. Such bottom layer 28 mayprovide, for example, a suitable surface to which to apply an adhesive,especially if the top layer 142 of the existing mattress 120 is not sosuitable. Alternatively, a flange (not shown) of the upright wallassembly 130, similar to the previously described flange 32, can beattached as by stitching to the upright outer layer 140 of the existingmattress 120 either interiorly or exteriorly thereof. As will beappreciated, if the flange is attached on the inside of the uprightouter layer 140, the upright outer layer 140 must be detached to someextent from the top layer of the existing mattress 120. As will furtherbe appreciated, if the flange is attached to the exterior of the uprightouter layer 140, the flange material may be selected to have a patternsimilar to that of the upright outer layer 140 of the existing mattress120, or to that of another decorative pattern.

[0069] A zipper 146 is stitched or otherwise attached at or near theperiphery of the removable mattress cover 124, as is illustrated.Although not shown, an adhesive adheres to the top layer 142 of theexisting mattress 120. A suitable fill material 148 such as theillustrated foam layer is then inserted into the cavity provided by theupright wall assembly 130, with the adhesive holding the foam layertherein. The zipper 146 engages the zipper 136 thereby to secure theremovable mattress cover 124 to the existing mattress 120.

[0070] As can be seen in FIG. 13, the upright wall 132 is useful forenveloping the perimeter of the fill material 148 inward of the uprightwall 132. In the illustrated embodiment, the thickness of the fillmaterial 148 is less than the height of the adjacent upright wall 132.This reduces stress on the zipper fastening system as compared to overlysnug prior art mattresses and mattress covers. It will be appreciatedthat the thickness of the fill material 148 may alternatively be thesame as or greater than the height of the upright wall 132. As is shownin FIG. 14, the zipper 146 is easily accessible from the top of theretrofitted existing mattress 120.

[0071]FIG. 15 shows another embodiment of the present invention in whichan existing mattress 160 has been retrofitted to accommodate a removablemattress cover 164. In this embodiment, upper surface loop-and-hookfasteners 168 are secured at or near the perimeter of the top layer ofthe existing mattress 160, and mating loop-and-hook fasteners 172 aresecured to the underside and at or near the periphery of the removablemattress cover 164 as illustrated. The loop-and-hook fasteners 168 and172 can be attached to the respective top layer of the existing mattress160 and the underside of the removable mattress cover 164 in anysuitable manner, as by stitching for example. The loop-and-hookfasteners 172 engage the loop-and-hook fasteners 168 to secure theremovable mattress cover 164 to the existing mattress 160.

[0072] The removable mattress cover assembly need not be limited to oneside of the mattress base or existing mattress, and the claimedinvention contemplates removable mattress cover assemblies on both sidesof mattress. FIG. 16 shows an existing mattress 180 and a pair ofremovable mattress covers 182 fastened thereto in accordance with anexemplary embodiment of the present invention. The removable mattresscovers 182 are similar in construction to the removable mattress cover104 shown in FIG. 11, for example. A plurality of fasteners 184 areattached to the existing mattress 182 at the top and bottom thereof in amanner similar to the fasteners 108 in the existing mattress 100 shownin FIG. 11, for example. The removable mattress covers 182 are eachprovided with corresponding mating fasteners 186. Advantageously, thepair of removable mattress covers 182 enable two mattress types, forexample, firm or soft, to be incorporated into one mattress assembly.

[0073]FIG. 17 is a perspective view of an exemplary combination of aretrofitted existing mattress 200, a pair of upright wall assemblies202, and a pair of removable mattress covers 204 in accordance with thepresent invention. The existing mattress 200 is retrofitted with theupright wall assemblies 202 in a manner similar to that described abovewith respect to the upright wall assembly 130 and the existing mattress120 shown in FIGS. 13 and 14. Here, however, a plurality of wallfasteners 208, for example, the illustrated snap fasteners, are attachedto the upper rim portion of the upright wall assemblies 202. In asimilar manner, a plurality of cover fasteners 218 are attached at theperimeters of the removable mattress covers 204. The cover fasteners 218are fastened to the wall fasteners 208 fasten the removable mattresscovers 204 to opposite sides of the existing mattress 200. Suitableinner fill materials (not shown) are inserted between the existingmattress 200 and the respective removable mattress covers 204. As willbe appreciated, the top and bottom upright wall assemblies 202 may bethe same or different, for example, with respect to height andthickness. Similarly, the inner fill materials may be different onopposite sides of the existing mattress 200, as may be necessary ordesired.

[0074] Referring now to FIG. 18, there is shown yet another retrofittedexisting mattress 230 and an upright wall assembly 232 according to thepresent invention. In this embodiment, a plurality of fasteners areattached at an upper rim portion 240 of the upright wall 236, at a lowerrim portion or row 242 of the upright wall 236, and at an intermediateportion 241. A removable mattress cover with corresponding matingfasteners (not shown), such as the removable mattress cover 64illustrated in FIG. 7, can be adjustably attached to the upright wallassembly at different heights corresponding to different fastener rowsto accommodate, for example, different thicknesses or quantities of fillmaterials. As will be appreciated, any number of rows of fasteners maybe incorporated into the upright wall assembly 232, and the claimedinvention contemplates as many as the upright wall 236 can accommodate.Also, it will be appreciated that the upright wall 236 need notnecessarily be perpendicular or substantially perpendicular toaccommodate multiple rows of fasteners. That is, the upright wall 236may taper outwardly with respect to the upright outer layer 248 of theexisting mattress 230. Moreover, multiple rows of fasteners may beprovided in a mattress or retrofitted existing mattress embodying upperand lower upright wall assemblies. As will further be appreciated, if arow of fasteners is not used, the upright wall 236 may be foldeddownward back over itself. The folded down portion can then be coveredby the removable mattress cover fastened to the next lower row offasteners in the upright wall assembly 232.

[0075] As will be appreciated, the present invention realizes severalbenefits. The removable mattress cover assembly can be made part of anynewly constructed mattress or be retrofitted into any existing mattressin any on-site location, for example, a home, a hotel, a business, acamper, a boat, or a health care facility. Existing mattresses withstained or torn covers may be retrofitted with the removable mattresscover assembly in a matter of minutes. Indeed, no new mattress productpurchase is required in order to install the removable mattress coverassembly.

[0076] Moreover, in a marine environment berth where space is usuallytightly confined by three side walls, a mattress or retrofitted existingmattress according to the invention can be sized to actually touch themultiple sides of the sleeping berth. The removable mattress cover isconveniently attachable and detachable at the top of the perimeter ofthe upright wall assembly. Advantageously, the removable mattress covercan be fastened to the mattress or retrofitted existing mattress whilean individual is physically on top of the mattress, thus eliminating theneed to completely remove the mattress from the berth to gain access tothe fasteners below the mattress top layer or surface, as was the casein the prior art.

[0077] For home use, the product is easier for headboard and footboardinstallation that heretofore has been an obstacle or barrier to fasteneraccess. Removal and installation also are simplified because the uprightwall of the upright wall assembly is flexible and can move a few inchesin a standard sized mattress towards or away from the top layerperimeter, allowing some “play,” and thus avoiding the need to pull andtug the top layer to get beneath it to access the fasteners. The toplayer heretofore was not easily accessible, particularly in a marine orRV environment.

[0078] The removable mattress cover can be installed regardless of thefill material thickness beneath the cover surface, as the upright wallassembly will naturally adjust to increased or decreased thickness.Known past products are limited by thickness restrictions. In prior artmattresses, overstuffing occurred and resulted in excess stress on theperimeter fasteners or attachments, rounding of the mattress cover, orexcess tension at the fasteners or attachments. The upright wallassembly in accordance with the present invention reduces the likelihoodor prevents such stress at the perimeter fasteners and attachments, andreduces or prevents rounding of the removable mattress cover.

[0079] It will be appreciated that multiple styles of the mattress orretrofitted existing mattress are possible, including for exampleconventional sized mattresses, a pillow top mattress, a one-sided, ortwo-sided mattress, depending on, for example, particular applicationand demand. Also, different shapes can be produced including regular ornon-rectangular shapes, including round, oval, triangle, square, heart,or other shaped mattresses. The removable mattress cover according tothe present invention can be easily duplicated and reproduced, replaced,removed and cleaned or modified. Due to its simple design, especiallydifficult shapes having inside corners or indentations such as commonboat mattresses or antique four post beds can be made without unduestress on closing seams and attachment materials.

[0080] Free and unrestricted movement of the upright wall of the uprightwall assembly yields a “pillow top posturizing effect” that allows theremovable mattress cover to adjust to differences in body weight, bodypositions, or different sleeping partners. The removable mattress coverassembly reduces the “hammock effect” experienced by covers secured orheld in place at relatively lower positions, which cannot move orrespond to different pressures.

[0081] The upright wall assembly in accordance with the presentinvention enables mobility of the inner fill material, such as foammaterial, and the ability for the inner fill material to conform,respond, and adjust to pressure areas. Heretofore, quilt covers wereused to cover the inner foam material, which masked the actual feel,comfort qualities and benefits of the inner foam material, so that theuser felt the quilt material instead or more so. The removable mattresscover assembly of the present invention alleviates this problem byproviding a removable mattress cover that need not necessarily be aquilted cover, but rather any suitable material cover to take advantageof the benefits of the inner fill material underneath. In this regard,the removable mattress cover may be made of any suitable material, forexample, 180 percale sheet material, 200 percale, or 300 percale, acenter 1 oz. fiber or {fraction (1/2)}oz. fibre. A bottom sheet with180, 200, 300 percale may be multi-needle quilted to an upper sheet toform the removable mattress cover. Such materials allow instant feel ofmaterials beneath the removable mattress cover. Inner fill materialsbeneath the removable mattress cover need not be sewn, allowing thematerials to react as designed without sewing tension restrictions. Aswill be appreciated, the removable mattress cover can be made ofconventional quilted layers and fill material or non-quilted materials,it being understood that the claimed invention contemplates a removablemattress cover that is flexible and removable with respect to an uprightwall assembly or a top layer of a mattress base or a retrofittedexisting mattress.

[0082] Two exemplary materials that may be used to accentuate the “feel”of the inner fill materials include, for example, visco-elastic material(for example two inches thick) or memory foam. The upright wall andremovable mattress cover move and adjust in response to movement andadjusting in the memory foam. Together the upright wall, removablemattress cover and memory foam adjust and conform to body weight, andwork together to fully utilize the memory foam properties withoutrestrictions. In another embodiment, the inner fill material mayconstitute a soft latex foam. Such product yields or reacts in a similarparallel manner as the removable mattress cover adjusts when body weightis applied. The soft latex or memory foam conforms to pressure, fillingin all body curves from wrists, elbows, back, knees, and ankles todistribute the body weight more evenly and disperse body surfacepressure.

[0083] The upright wall assembly also permits materials used beneath theremovable mattress cover to be wider and/or longer, increasing theactual sleeping area surface, because the upright wall construction isnot undulated, interrupted or restricted by perimeter gussets or extrainner attachment devices as in the prior art.

[0084] The adhesive strips installed on the top layer of the mattressbase, the top layer of the retrofitted existing mattress, or the bottomlayer of the upright wall assembly, as the case may be, prevent or atleast reduce the likelihood of the inner fill materials from migrating,bunching, or buckling during entry position, turning, and exiting. Theupright wall assembly reduces unnecessary additional seams, therebyreducing thread skips and separation during normal wear and use. Stresspoints also are reduced due to free movement of the upright wall of theupright wall assembly.

[0085] Although the invention has been shown and described with respectto certain preferred embodiments, it is obvious that equivalentalterations and modifications will occur to others skilled in the artupon reading and understanding this description and accompanyingdrawings. The present invention includes all such equivalent alterationsand modifications and is limited only by the scope of the followingclaims.

1. A removable mattress cover assembly for attachment to a mattressbase, comprising: an upright wall assembly including an upright wall forattachment to a top of the mattress base and one or more wall fastenersattached at or near a top of the upright wall; and a removable mattresscover including one or more cover fasteners that are matable withrespective wall fasteners, wherein when the cover fasteners are fastenedto the wall fasteners, the removable mattress cover covers the top ofthe mattress base and the upright wall is substantially perpendicular tothe removable mattress cover.
 2. A removable mattress cover assembly asset forth in claim 1, wherein the upright wall assembly further includesa second row of a plurality of wall fasteners attached to the uprightwall and spaced below a plurality of fasteners at or near the top of theupright wall.
 3. A combination, comprising: a removable mattress coverassembly as set forth in claim 1; and a mattress base, wherein theupright wall is attached to the mattress base.
 4. A mattress as setforth in claim 3, wherein the mattress base is an existing mattress. 5.A removable mattress cover assembly as set forth in claim 1, whereinwhen the one or more cover fasteners are fastened to the one or more allfasteners, the removable mattress cover covers the top of the mattressbase and the cover fasteners project upwardly relative to the top of themattress base.
 6. A method of making a mattress, comprising the stepsof: providing a mattress base and an upright wall; attaching the uprightwall to a top of the mattress base; attaching one or more wall fastenersat or near a top of the upright wall; providing a removable mattresscover including one or more cover fasteners that mate with respectivewall fasteners; and fastening the one or more cover fasteners torespective wall fasteners, whereby the removable mattress cover coversthe top of the mattress base and the upright wall is substantiallyperpendicular to the removable mattress cover.
 7. A method as set forthin claim 6, further including attaching a second row of a plurality ofwall fasteners to the upright wall spaced below the plurality offasteners at or near the top of the upright wall.
 8. A method as setforth in claim 6, wherein the mattress base includes an upright outerwall depending from the top, and wherein the upright wall is attached tothe mattress base in substantially coplanar relation to the uprightouter wall of the mattress base.
 9. A method as set forth in claim 6,further including the step of inserting a layer of fill material betweenthe top of the mattress base and the removable mattress cover, the layerof fill material having substantially the same footprint as thefootprint of the top of the mattress base.
 10. A method of retrofittingan existing mattress with a removable mattress cover, comprising thesteps of: attaching an upright wall to a top of the existing mattress;attaching a one or more of wall fasteners at or near the top of theupright wall; providing a removable mattress cover including one or morecover fasteners that are matable with the respective wall fasteners; andfastening the one or more cover fasteners to respective wall fasteners,whereby the removable mattress cover covers the top layer of theexisting mattress and the upright wall is substantially perpendicular tothe removable mattress cover.
 11. A method as set forth in claim 10,further including attaching a second row of a plurality of wallfasteners to the upright wall spaced below the one or more fasteners ator near the top of the upright wall.
 12. A method as set forth in claim10, wherein the existing mattress includes an upright outer walldepending from the top, and wherein the upright wall is attached to theexisting mattress in substantially coplanar relation to the uprightouter wall of the existing mattress.
 13. A method as set forth in claim10, further including the step of inserting a layer of fill materialbetween the top of the existing mattress and the removable mattresscover, the layer of fill material having substantially the samefootprint as the footprint of the top of the existing mattress betweenthe top of the existing mattress and the removable mattress cover.
 14. Amattress, comprising: a mattress base; one or more upper surfacefasteners attached to a top of the mattress base; and a removablemattress cover including one or more cover fasteners that are matablewith the respective upper surface fasteners; wherein when the one ormore cover fasteners are fastened to respective upper surface fasteners,the removable mattress cover covers the top of the mattress base and theone or more cover fasteners project upwardly relative to the top of themattress base.
 15. A mattress as set forth in claim 14, wherein themattress base is an existing mattress.
 16. A method of making amattress, comprising the steps of: providing a mattress base; attachingone or more upper surface fasteners to a top of the mattress base;providing a removable mattress cover including one or more coverfasteners that are matable with respective of upper surface fasteners;and fastening the cover fasteners to respective upper surface fasteners,whereby the removable mattress cover covers the top of the mattress baseand the one or more cover fasteners project upwardly relative to the topof the mattress base.
 17. A method of retrofitting an existing mattresswith a removable mattress cover, comprising the steps of: attaching oneor more upper surface fasteners to a top of the existing mattress;providing a removable mattress cover including one or more coverfasteners that are matable with respective upper surface fasteners; andfastening the cover fasteners to respective upper surface fasteners,whereby the removable mattress cover covers the top of the existingmattress and the one or more cover fasteners project upwardly relativeto the top of the existing mattress.